Workshops: Fundamentals of stamping and forming machines with focus on mechanical presses

This seminar is intended to provide a common understanding and orientation for your employees regarding terms and machine concepts of modern sheet metal forming production equipment. Hereby an interdisciplinary know-how for successful teamwork is established.

Topics:

  • Overview of sheet metal cold forming machines and press systems
  • Design and components of mechanical presses
  • Equipment for press automization
  • The 1×1 of motion optimization aimed towards increasing stroking rates
  • Characteristic properties of press drives
  • Die design oriented to the press and tailored to the specific machine

Workshops for setters in stroke rate and process optimization for all major press brands

Setting up and optimizing a transfer or progide press line, maybe even with a servo press, is a complex affair. Learning a structured approach and understanding the interrelationships of the drive and sensor technology provide a remedy here. Setters who master the principles of cam based programming are not only able to set optimal and thus process-stable, smooth and highly productive cams, even the tool set-up time is significantly shortened, errors are detected and corrected within a minimum of time.

Topics — Contents Theory part:

  • Programming principles & best practice for optimal set-up.
  • Setting up transfer movements based on start & stop angles
  • Identifying reasons for process limitations and finding countermeasures

Topics — Content’s Practical part:  

  • As-is assessment of the process at production stroke rate and determination of process bottlenecks
  • Method for measuring crucial process parameters
  • Optimization of the settings of the respective press (conv. or servo), 3-axis transfers and sensor technology

Servo tailored die design workshop to truly utilize servo technology in terms of output, die endurance and part quality

With their flexible motion profiles, servo presses have become the benchmark in the production of sheet metal forming parts. The ability to adjust the slide speed and the slide stroke to the tool conditions allows an optimum output to be achieved.

Topics:

  • Layout and operating principle of servo presses
  • Press characteristics and their meaning in the context of die design
  • Stroke rate determining parameters of servo presses
  • Selection of standard parts suitable for servo presses

Systematic Reduction of Setup Time

Quick Die Changeover Workshop: Shorten set-up times based on SMED with a lasting effect by unleashing the full potential of your organization

All efforts to achieve a permanent and continuous reduction of setup times will only be successful if all the methods are introduced holistically and based on a systematic approach. In this workshop, we will train these methods and illustrate their function and effects in real-life use.

The basic methodical and theoretical principles of setup according to SMED will be worked out on the first workshop day particularly for practitioners. For this purpose, we will work on model machines that simulate a real setup process in a realistic way and illustrate all phases of an optimization process very clearly.

This methodology combines the experience of the employees involved in the setup processes with a structured approach according to SMED. Putting this into practice then becomes almost routine.

Topics:

  • Introduction to setup time optimization
  • SMED – Basics
  • Standardized setup documentation
  • Methodical changeover analysis
  • Internal & external setup time
  • Parallel changeover steps
  • Workplace organization / 5S
  • CIP – Continuous Improvement
  • Structured problem solving
  • Error prevention / Poka Yoke
  • Sequence optimization
  • Technical changeover optimization
  • Assurance of continuity
  • Repeated practical exercises

Services: Performance and output benchmark as a service for all press manufacturers

How optimal is your setting? What level is your equipment operating at? Is output being wasted or can productivity be increased by optimizing the settings? What are the causes of this and what measures can be taken to remedy the situation?

Would you like to have answers to these questions and get feedback on how efficiently your presses are being operated in the press shop? Opt for a performance benchmark and get answers to these questions.

Scope of services:

  • Analysis of the ACTUAL setting parameters and examination in the real production process
  • Detection and analysis of process bottlenecks
  • Deriving and implementing optimized setting values to increase the stroke rate and/or to reduce the wear on the equipment
  • Discussion with suggestions for improvement

Stroke rate and process optimization on servo and conventional systems

The aim of this service is, by optimal adjustment of the machine parameters, the achievement of the best possible

  • part quality
  • output
  • Increased Tool life & reduced machine wear and tear

on your forming machine.

Scope of services:

  • Analysis of the ACTUAL adjustment values and evaluation within the real production process
  • Identification and evaluation of obstructing process bottlenecks
  • Adjustment of optimal, part- and tool-specific motion curves for servo-press, 3-axis transfer and coil feed
  • Testing of new setup parameters on the system with the aim of process optimization and stroke rate increase

Virtual kinematic transfer simulation for collision detection and design optimization

Would you like to get the maximum out of your transfer press without any detours? Are you tired of revision and optimization loops for new dies or do you want to be able to manage a tool relocation project safely and without unnecessary downtimes? Call on the service of virtual kinematic simulation of machine and die movements. The digital twin of your tool design reveals collisions between the moving machinery and tool components, thus ensuring clearance.

Scope of services:

  • Processing of 3D CAD data for kinematic analysis based on *STEP / *IGS data – CAD neutral, independent of your used CAD system
  • Visualization of the moving 3D geometry for collision evaluation
  • Identification of optimization potential for increasing the stroke rate

Motion and flow simulation of new forming equipment to safeguard investments

New press line or process concepts often have unique selling propositions and significant potentials. For a better evaluation of the associated opportunities and risks, the part flow from feeding to removal of the finished part can be virtually and kinematically represented.

Critical spots become visually apparent and controllable. The complex interaction of all movements can be optimized in terms of timing already in the planning stage and the expected output rate can be calculated.

Scope of services:

  • Sequence simulation of all relevant, moving 3D geometries of parts, press line and tools on the basis of the transmitted 3D CAD data.
  • Set-up and optimization of movements on the basis of the designed machine.
  • Simulation report
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